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A New Environmental Lubricant Supports Key Subsea Boosting and Compression Technology

13OTCB-P-915-OTC

Castrol: Chris Morrissey and John MorrisOneSubsea: Anders Brunvold

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1. Overview of Subsea Boosting/Compression Technology2. Meeting Evolving Health, Safety and Environmental Legislation3. Functional Requirements of the Lubricant4. Lubricating Fluid Development Process5. Mechanical Seal Validation Testing6.  Conclusions and Next Steps

Contents

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Advantages• Increased production• Increased recovery• Improved flow assurance• Increased flexibility in 

field development solutions

Higher capacity units require a lubricating oil with:‐1. Higher thermal rating2. Compliance with 

environmental legislation in key regions

3. No compromise on performance and reliability

Overview of Subsea Boosting and Compression Technology

Subsea boosting by OneSubsea – Total Flexibility

SPP

WGC

MULTIPHASE

0

50

100

150

200

250

0 10 20 30 40 50 60 70 80 90 100

GVF [%]

Diffe

rential Pressure [bar]  

HYBRID

Wet Gas Compressor

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• Lubricate hydrodynamic bearings, mechanical seals and other internal components

• Act as cooling medium in motor, pump or compressor components

• Keep certain insulation properties in motor and power penetrators

• Transport wear particles to filters• Act as a barrier between sea/process and 

internal components

OneSubsea Pump / Compressor Lubricant Function

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Meeting Evolving Offshore Environmental Legislation

North East Atlantic (OSPAR)UK, Norway, Netherlands + others

Each component testing for:-• MARINE BIODEGRADATION• BIOACCUMULATION• MARINE TOXICITY

North East Atlantic (OSPAR)UK, Norway, Netherlands + others

Each component testing for:-• MARINE BIODEGRADATION• BIOACCUMULATION• MARINE TOXICITY

Commitment to reduce the discharge of non-compliant chemicals

GULF OF MEXICOProduct level toxicity testing onlyNo sheen on water surfaceBRAZIL – No specific environmental testing for subsea control fluids

GULF OF MEXICOProduct level toxicity testing onlyNo sheen on water surfaceBRAZIL – No specific environmental testing for subsea control fluids

Emerging LegislationNo specific offshore legislation.Drive for OSPAR compliance

Emerging LegislationNo specific offshore legislation.Drive for OSPAR compliance

UK OCNS ‐ RATING ‐ A  B  C  D  E

Decreasing Environmental Hazard

REGIONAL PRODUCT/CHEMICAL  RATINGS

Norwegian Colour Rating for chemicals

Green Compliant (no testing required)

Yellow Compliant

Red Substitution Plan Required

Black May not be discharged

ALGAE

CRUSTACEANS

FISH

SEDIMENTREWORKERS

SPECIES TOXICITY TESTING

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Fluid Development Process

Property Requirement

Thermal stability

150°C +

Electrical Breakdown

>20Kv (EIC 156)

Environmental Performance

OSPAR compliantNo substitutablechemistry

Key Product Specification

Step 1 Raw material identification(performance & environmental screening)

Step 4

Additive level optimisationStep 3

Formulation screeningStep 2

Step 5

Rig Testing

Equipment Testing

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Optimising Formulation for Breakdown Voltage• 20 Kv limit for Breakdown 

voltage• Tested by running IEC 156 

test• Results are variable so run in 

triplicate and averaged• Also tested with 

contamination fluid

VARYING ANTI‐CORROSION LEVELS

VARYING AW and SEAL SWELL ADDITIVE LEVELS

No Add

Electrodes in fluid(IEC 156 Test)

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Other Fluid Chemistry Validation Testing

3. Motor InsulationCompatibility Testing

Castrol oil ‐ Increasing levelsof Anti‐Corrosion additive150C 4 weeks

1. Thermal Stability Testing

2. Fluid Drying Test with Coalescing Filter

Water Droplets

Before Drying After Drying

Typical MineralOil, 150C 4 weeks

Castrol oil – Final blend220C – 12 weeks

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• Mechanical seal qualification• Motor internal components compatibility testing• Elastomeric and thermoplastics accelerated aging tests• Motor insulation testing IEC 60156• Verification of mechanical components in full scale test rigs• Lubricant benchmark testing• Lubricant back compatibility tests (Castrol)

OneSubsea: Qualification testing

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Pump application• Standard application 250°F  (121°C)• Hot process application 400°F  (204°C)

Wet Gas Compressor application• Contra rotating (4500RPMx2) 

OneSubsea: Full scale test rigs

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• Example of inadequate thermal behaviour of other lubricant in mechanical seal.

• Example of good thermal behaviour of lubricant in mechanical seal.

Mechanical seal testing

Laquering on OD of seal ring due tothermal breakdown of lubricant.

No laquering or discoloring of seal ring

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• A new barrier oil has been developed which provides extreme thermal stability, good electrical insulation and lubricity, and fully meets the tightest OSPAR environmental legislation

• Performance assurance has been achieved by benchmarking the fluid through testing against existing lubricants of known performance and track record

• OneSubsea would like to offer clients an alternative environmental oil solution, which has little or no additional risk to reliability, and with the benefits of higher performance

• Further rig testing and real life machine running hours will ensure maximum confidence before launch

• For wet gas compressor the contra-rotating seal tests and full compressor trial are planned, with TRL4 to be reached by March 2014

• Next steps for the hot pump development (400F/ 204C) is to qualify the elastomers/polymers over a wide temperature range for extended periods

• Market demand for larger capacity machines will push performance limits of the barrier oil, for which OneSubsea is well prepared

Conclusions and Next Steps

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Thank You

Any Questions ?